Special Instructions
1.1. Installation Instructions
2.2. Priming Pump After Installation
3.1. Control Switch Installation Procedure
4.1. Schematic
5.1. Adjustment Procedure
6.2. Stops
7.2. Hydraulic Fluid
8.2. Reservoir Filling And Operation

Installation Instructions

------ WARNING! ------

Disconnect batteries before performance of any service work.


------ WARNING! ------

Stop the engine, lower the bucket to the ground, move the control levers backward and forward to release the pressure in the hydraulic system. Slowly loosen the cap to release any pressure in the hydraulic tank. Let the hydraulic oil become cool before any lines are disconnected in the hydraulic system.


The coupler frame group is designed to pin to the loader in the same manner as a AVSpare bucket, using the same pins, keeper bolts, and spacer washers [6 - 1.60 mm (.063 in) thick and 4 - 3.0 mm (.118 in) thick] supplied with the loader. Use spacer washers to shim the lower hinge as tight as possible between the frame group bosses and lift arm bosses. This will help prolong the life of the hinge pins and bearings by restricting the amount of foreign material that can be forced into the hinge area when loading and backdragging.

Remove front cover plate from the machine. The mounting bracket should be placed in order to satisfy the following criteria:

* Do not install the pump group near the radiator.
* Keep the lines group and wiring away from rotating components such as fans and drive shafts.
* Do not install the pump group near engine exhaust components such as manifolds and turbos.
* Install the pump in a location that is readily accessed for service and the reservoir fill port is accessible for filling.
* Choose a location to allow the pump to be parallel to the ground when the machine is on level ground.
* Choose a mounting surface with sufficient strength to support pump group weight.
* Choose a mounting location that will not interfere with the normal servicing of the machine.

For bolted mounting, use the mounting bracket as a template and drill four 9 mm (0.35 in) holes in the mounting surface. Bolt the bracket to the mounting surface using four bolts, four washers, and four locknuts.

For welded mountings, use a 6 mm (0.25 in) fillet weld along the sides and top of the bracket.

NOTE: The mounting bracket surface must have sufficient strength to withstand the weight of the pump group plus the loads due to vibration. Reinforce the mounting surface as needed to support the operating loads.

Bolt the pump to the mounting bracket using five bolts, five washers, five locknuts, and one star washer.

Pump Group
(1) To switch. (2) Pump group. (3) Earth cable. (4) 9.5 mm (0.375 in) Bolt, Flat washer, Locknut. (5) 8.00 mm (0.3125 in) Bolt, Flat washer, Locknut. (6) Mounting Bracket.

Detail F
(1) Front cover plate. (2) Power cable.

Detail E
(3) Mounting bracket.

Route the pump switch cable underneath cab and then up through rubber boot around steering column. Install the pump switch on the right side console in the wheel loader cab. Drill 3.4 ± 1.4 mm (0.134 ± 0.055 in) diameter holes for switch mounting screws. Assemble the switch box and secure box with mounting screws.

NOTE: Do not apply labels to switch at this time. Route the pump power cable (2) between pump solenoid and starter solenoid. Secure pump power cable and switch cable with 6K-0806 nylon ties.


Do not attempt to power the pump until hydraulic installation is completed and the pump is filled with ATF (automatic transmission fluid).

Inside Left Lift Arm
(2) Lift arm. (A) 1030 mm (40.5 in). (B) 250 mm (10.0 in). (C) 25 mm (1.0 in). (D) 30°. (E) 20°. (F) 178 mm (7.00 in). (G) 45 mm (1.75 in). (H) 127 mm (5.0 in).

Weld hose clamp plates to inside of left lift arm.

Differential Lever Arm
(3) Differential lever arm. (K) 127 mm (5.00 in). (L) 38 mm (1.5 in).

Weld hose clamp plates to inside of differential arm and tilt cylinder bracket.

Hose Assemblies
(1) 90° Adapters. (2) Hose assemblies. (3) Clamp. (4) Hose assembly. (5) Clamp. (6) Coupling.

Install 90° adapters (1) into pump ports C1 and C2. Install hose assemblies (2) to pump adapters and route up through the tilt cylinder and lift arm pivot areas and down lift arm. Clamp hose assemblies to the tilt cylinder bracket and the first two plates on lift arm with clamp halves, cover plates, and bolts (5). Move lift arms to the fully raised position and adjust hose lengths as required to avoid tightness and/or looseness through the pivot area.

Cut hose assemblies to length and install male J.I.C. reusable coupling (6).

NOTE: The ends of the male J.I.C. re-usable coupling should be located midway between the two clamps as shown above.

Connect hose assemblies (2) to hose assemblies (4) and route down lift arm, over to differential lever ear, down differential lever, and out to "C" pin boss on coupler frame. Clamp hose with clamp halves, cover plates and bolts. Move coupler to avoid tightness and/or looseness through all pivot areas. Remove plugs in cylinder ports and install 90° adapters. Cut hose assemblies to length, install female J.I.C. re-usable coupling, and connect the hoses to the cylinder adapters.

Check to make certain all fittings, connections, and clamps are tight. Fill the pump with ATF (automatic transmission fluid) and activate the pump several times to rid the system of air. Check all fittings again to make certain there are no leaks. Install labels on switch to correspond with switch movement and coupler action. Refill the pump with ATF as required.

Priming Pump After Installation

New system installation requires proper priming to avoid pump failure. A pump is said to be "primed" when the internal cavity is full of oil and the air has been expelled.

Prime a pump as follows:

1. "Crack" or remove the high pressure line at or near the cylinder.
2. "Jog" the unit until oil flow is clear. (Air is absent).
3. Retighten or replace hose.

On systems that fail to prime or lose their prime, check the following:

1. Proper reservoir size. (See reservoir section).
2. Partially clogged suction filter. (See filter section).
3. A loose or improperly installed suction hose or pick up tube.
4. A bad front pump seal.
5. A solid fill plug in reservoir with no vent. (See reservoir section).
6. Oil that is too thick (See hydraulic fluid section), or contaminated with water. (See reservoir section).
7. Occasionally a pump will not prime itself because a check valve spring in the high pressure port is too "stiff" or the spring retainer is turned down too far. If this condition is expected, loosen the spring retainer (it is found in the 3/8 inch high pressure outlet port), energize the pump to prime it, and then turn the retainer back to the correct depth. (See section on check valves).

Control Switch Installation Procedure

------ WARNING! ------

Disconnect the battery before performance of all service work.


The location for the control switch for the quick coupler.

(1) Use existing screws to secure bracket. (2) Right side console in wheel loader cab.

1. Locate an unused switch knockout or drill a 12 mm (0.4375 in) hole in the operator station to install the power cable (3).
2. Route the pump control power cable (3) from the pump through an existing weather sealed hole under the operator station and into the area where the toggle switch will be located.

(4) Jumper bar. (5) Decal. (A) Bottom View. (B) Top view.

3. Switch jumper bar must be on side shown. Decals must be located in this position.

Toggle switch terminals.

4. Attach the four colored wires to the toggle switch terminals. Tighten the water tight connector nut (5), making sure the wires are not caught in the switch box.

5. Place the gasket and toggle switch box (6) on the toggle switch cover (8) and install two screws (9).
6. Secure the power cable (7) with 6K-0806 wiring ties where possible.

7. Install the grommet (10) to protect power cable (3).

8. Mount the breaker (13) in an accessible location.

Several factors to consider when mounting the breaker:

* Keep breaker away from high heat areas such as exhaust manifolds and turbos.
* Locate breaker so that power wires will not rub against adjoining hoses, brackets, or rotating components.

Using the breaker as a template to locate and drill two 8 mm (0.315 in) holes through the mounting surface. Attach the breaker (13) using bolts (18), washers (14), and nuts (15).


Plastic breaker housing may be damaged if mounting bolts are over tightened.

9. Attach the power cable (12) to the "bat" terminal. Route the power cable (17) to the pump solenoid. Cut the excess wire from power cable (17) and crimp lug (16). Solder the lug to power cable after crimping. Attach power cable (17) to the pump solenoid. Secure the power cables (12, 17) to the machine with 6K-0806 wire ties.
10. Attach the power cable (17) to the starter solenoid and the "aux" terminal on the breaker (13).
11. Connect machine battery cables.
12. Fill reservoir to within 13 mm (0.5 in) of the top. Use Automatic Transmission Fluid (ATF).
13. Cycle the coupler cylinder in and out. Add ATF until all trapped air is purged from the system.


Adjustment Procedure

The combined tolerances and clearances between the machine and the quick coupler must allow the quick coupler stops to protect the machine linkage. The exact location of the quick coupler stops can only be determined when the quick coupler is pinned to the machine.

Checking the stops and making any adjustments to stops that may be necessary is the responsibility of the dealer during pre-delivery service. Adjustments to stops is not a warranty item. Maintenance of stops because of wear or other factors during attachment usage is the responsibility of the user.


Rack Back Stop Adjustment Procedure

Stops on loader attachments are necessary to protect the attachment, tilt linkage, and cylinder from highly leveraged forces.

1. Engage an attachment to the quick coupler frame and insert the coupler locking pins in the locking ears on the attachment.
2. Tilt the quick coupler to the full rack back position. Raise the loader lift arms until the quick coupler stops are closest to the arms. See illustration below for the exact location.

(1) Maximum fold up occurs at the point of full cylinder extension. (2) Three pins are aligned. (3) Bucket in maximum fold up position. (4) Hinge pin height at carry position. (5) With no weight or external force on the bucket, there could be a gap between the loader arm and rack back stop. This gap is normally caused by the combined tolerances of the loader lift arms, tilt linkage, and attachment. Whether the stop should be adjusted is determined by fully extending the tilt cylinder, forcing all "play" out of the loader arms, linkage and attachment, and seeing if the stops contact. (6) Ground line.

3. Keeping the tilt cylinder extended, slowly raise the lift arms to the point where the stops and lift arms are closest together. This should be the point of maximum fold up and will occur near the hinge pin height at carry position (see AVSpare machine specifications). This is the only position where rack back stops and loader arms should contact.
4. If the stops make contact with the loader arms before the point of maximum fold up, you will need to remove material from the stop until the stops and loader arms are making contact at the point of maximum fold up.

If the stops do not make contact with the loader arms at the point of maximum fold up, material may need to be added to the stop. To determine if material should be added do the following:

a. With the attachment in the maximum fold up position, remove all play in the tilt linkage by forcing the attachment back toward the loader arm. Push the bucket against an immovable object until the machine linkage offers a small resistance to further movement.
b. Measure the amount of the gap between the stops and loader arms. If no gap exists, no adjustment to the stop is necessary. If a gap exists, add enough material to the stops to maintain contact in this position.

Dump Stops For Wheel Loaders

Dump stops should contact the loader arms only when the milled surfaces of the tilt link and cross member are making contact.

To determine correct stop position do the following:

1. Raise the loader arms to the position of maximum hinge pin height at full lift (see AVSpare specifications for maximum hinge pin height).
2. Place the bucket in the full dump position.
3. If all contacts are being made, no adjustment is needed. If there is a gap between the stops and loader arms, add enough material so that stops do contact the loader arm. If the milled surfaces of the tilt linkage and cross member are not making contact, remove enough material from the stops until the milled surfaces do make contact.

Hydraulic Fluid

For operating temperatures between -43° C to 65° C (-45° F to 150° F) use Automatic Transmission Fluid (ATF). Temperatures outside this range are not recommended. For emergency cases when outside recommended operating temperature, contact your AVSpare dealer.

Reservoir Filling And Operation

Use recommended fluid.

Fill reservoir with the approved fluid as specified on the label next to the fill hole.

Correct filling And operation procedure.
1. Fill reservoir to within 13 mm (0.50 in) from the top with all the cylinders in the fully retracted position.
2. Operate unit several times starting with short cylinder strokes and increasing length with each successive stroke.
3. Recheck oil level often and add as necessary to keep pump from picking up air.
4. After system is completely purged of air, collapse all cylinders, check oil level in reservoir, and install the filter/breather plug provided.


Do not use a solid plug or a fill cap without a filter breather element. Damage to pump and/or reservoir will result.

Reservoir Tips And Comments
1. In most cases the reservoir is made to be mounted either vertically or horizontally and improper mounting will not allow it to be filled to capacity.
2. On units with a remote reservoir, try to mount the reservoir above the pump whenever possible to "flood" the inlet.
3. One of the functions of the reservoir is to keep the oil in the proper temperature range. If the reservoir cannot dissipate enough heat, increase the size in order to bring the oil temperature down to the proper level.